Multivariate color system with texture application

ABSTRACT

Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/472,336, filed May 15, 2012, which is a continuation of U.S. Pat. No.8,182,903, filed on Feb. 3, 2009, which is a U.S. National StageApplication corresponding to PCT Application No. PCT/US08/63124, filedon May 8, 2008, entitled “Multivariate Color System with TextureApplication,” which claims the benefit of priority to U.S. ProvisionalPatent Application No. 60/916,803, filed on May 8, 2007, entitled“Multivariate Color System.” This application is also a continuation ofU.S. Pat. No. 8,268,106, filed Apr. 12, 2012. The entire content of eachof the aforementioned patents and patent applications is incorporatedherein by reference.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

This invention relates to translucent and/or transparent polymer-basedpanel assemblies that incorporate colors through applied colored filmlayers.

2. Background and Relevant Art

Laminated translucent panel systems have achieved a wide utility indesigned architectural assemblies and applications, as well as lightingand display applications. One of the main facets of significant interestis the ability to add color to such panel systems. Translucent panelsystems come in a variety of forms and assemblies ranging fromcomposites to products produced from polymers to glass. Traditionalmeans of achieving color with the aforementioned substrates are throughpaints and coatings, dye and pigment concentrates or dispersants, orthrough adhesion of colored films, fabrics or papers. Many of theaforementioned coloring systems introduce aesthetic, performance ormanufacturing constraints when combined with the aforementionedpolymer-based or glass-based panel systems.

One category of methods to achieve a colored translucent or transparentthermoplastic panel is through direct application of color throughscreen printing or painting. With screen printing, ink is applied to thesurface using traditional screen printing methods. Drawbacks of screenprinting include the fact that the ink may be scratched off of the panelsurface. In addition, the ink typically needs to be bonded to the panelwith bonding additives that are often solvent-based and often produceundesirable volatile organic compound (VOC) emissions.

Painting is another way of applying color to the surface of a panel.Like screen printing, paint may also be scratched from the surface ofthe panel. Additionally, painting, and more particularly cleanup frompainting, also results in undesirable VOC emissions. Moreover, colors orimages applied through screen printing or painting are only correctlyviewable from one side of the panel. Also, panels colored or decoratedusing these methods tend to require cure times of between four andtwelve hours, during which time the panels require special storage andpossibly drying units.

A second category of methods for achieving a colored translucent ortransparent thermoplastic panel is through the infusion of color intothe surface of the panel. One method of this category is dye sublimationprinting, during which solid sources of dye, such as a printed transferpaper, are heated, placed in contact with a receiving substrate and theprinted color or image is transferred to the substrate and subsequentlycooled. This method results in the color or image penetrating thesubstrate such that it is more resilient to surface scratches. Moreover,the colors or images produced using this method may be viewed equallywell from either side of the panel. The dye sublimation method, however,requires considerable technical expertise to create the digital masterfiles and an understanding of the interaction of the dye with thesubstrate. Dye sublimation is also a capital-intensive operation thattends to require specialized printing equipment.

A second method in this category for infusing color into a translucentor transparent thermoplastic panel is by driving pigment into thesurface chemically. For example, one conventional mechanism includesbombarding the surface of a thermoplastic panel with solvent thattemporarily improves the solubility of the panel, thereby allowing dyescarried in the solvent to be transferred—and incorporated in—the matrixof the thermoplastic panel. Although this method is not entirely capableof rendering a predetermined image, the color driven into the surface ofthe panel in this way does yield a homogeneous color, and is moreresilient to surface abrasion than colors applied directly throughscreen printing or painting.

Unfortunately, this chemical process consumes large amounts of energy.The final quality also tends to be quite dependent on several processvariables and strict process control. The cycle time, and the regulationof temperature and solvent concentration are driving forces thatdetermine the quality of the finished panel. In addition, the equipmentrequired to employ this method is very costly. Furthermore, it takes asignificant amount of time to change over between one color and the nextbecause the system must undergo a cleaning cycle to flush out each colorafter use.

A third category of means for imparting color to a translucent ortransparent thermoplastic panel is through the use of a fabricinterlayer. Here, the method of imparting color to panels includes theuse of colored textiles. Using colored textiles to achieve a uniformpanel color, however, presents several challenges. One challenge is thatfabric has a texture of its own that remains visible through thetranslucent or transparent thermoplastic panel. In addition, whilecolored textiles may be used selectively to control the translucency ofa panel, they tend to impair the transparency of a panel.

Moreover, thermoplastic panels with textile interlayers are notgenerally suitable for wet environments without additional fabricationprecautions, because the fabric at the exposed edges of the panel willwick moisture into the interior of the panel. This wicking actionthrough the fabric layer introduces color distortion and staining withinthe panel. In addition, the viewability of color or an image dependsupon whether the color or pattern is woven into the fabric or printed ononly one side of the fabric. Also, fabric interlayers interfere withrecycling because they can not be easily separated from the resinsubstrate.

Furthermore, if more than one fabric interlayer is used, the mostvisible color will be that of the textile layer nearest the viewer,since colors are not blended or mixed when using textiles. In addition,care must be taken when laying up fabric interlayers because if they arenot placed straight and taut, the fabric layer can create the appearanceof waves. Still further, multiple layers of fabric may create the moiréeffect, which can be further exaggerated depending on the thickness ofany substrate interposed between fabric layers. Another considerationwhen constructing thermoplastic panels with fabric interlayers is thatthe fabric layer may not be on the surface. Moreover, care must be takento ensure that the fabric layer is laid up in the center of the overallpanel thickness to create a “balanced lay-up.”

Otherwise the panel, once constructed, will bow as it cools, and thebowing is an undesirable characteristic. Also, fabric layers withinpanels reduce the ability to thermoform the panels since the fabric willseparate or pull away under deep draw conditions due to the physicallimitations of the fabric. A last disadvantage of fabric layers withinpanels is that the fabric may wick moisture into the body of thelaminated panel if edges are exposed to wet environments.

A fourth category of technology for coloring a translucent ortransparent thermoplastic panel is through the use of films or “sheets”colored during manufacture with compounded pigments and dyes. Ingeneral, a “sheet” refers to that portion of a translucent polymericresin panel which, in its prefabrication state, is a unitary extrusionof material, typically measuring 2-6 feet wide and 8-12 feet long, andat least 1/32 of an inch in thickness. By contrast, a “film” refers to athin, membranous layer with the same planar dimensions as a sheet butwith a thickness ranging from 0.001 mils to 30 mils, but preferably 0.5mils to 20 mils, and most preferably 10 mils.

There are conventional mechanisms and apparatus that involve usingcolored films or sheets to create colored panels. Unlike panelsconstructed with embedded fabric layers, such conventional mechanismsinvolve no texture that is visible in panels formed with colored films.In addition, according to one conventional technology, such panels mustbe constructed with two co-polyester sheets, and include a backinglayer, which backing layer may also be colored. Accordingly, with thistechnology, there are at least two interfaces where air entrapment canbe a problem.

In addition, panels constructed for high-relief surfaces, whenincorporated with a fabric or a printed or a colored image, mayexperience wrinkling of the fabric or unusual distortion of the color orimage when captured between a top layer that is heavily textured and aback layer. The assembly may further require a laminating enhancinglayer (LEL), in addition to thermally compatible surfaces, to achievebonding and to facilitate the removal of air between the adjacentlayers. Removal of air from the panels is important, since any airpockets that remain in a finished panel can create a notch or point ofweakness with the laminate matrix that can result in crack propagationand failure in notch-sensitive thermoplastic materials. Applying alaminating enhancing layer tends to require additional processing steps,and increases material costs and introduces potential for contamination.In addition, the laminating enhancing layer must be uniformly appliedfor best results. Furthermore, the laminating enhancing layer, whetheran actual film or a sprayed-on material, is not generally the samematerial as the substrate. Similar to fabric interlayers mentionedabove, this dissimilarity contributes to the inability of such panels tobe reclaimed and recycled because the dissimilar resin material would bea contaminant in the recycling stream for the panel substrate whichconstitutes the majority of the panel.

A drawback of using colored films or sheets under the conventional artis that, typically, colored films are produced in large quantities toachieve economies of scale. As a result, the customer must purchase alarge quantity of a single color or image in order to obtain favorablepricing. This is compounded by the need to purchase multiple colors inorder to offer a variety of color choices. Such high-volume purchaserequirements can lead to unnecessary expense due to inventoryobsolescence. Alternatively, a purchaser may purchase small quantitiesof custom colored films at a much higher price for less than full-runquantities. As alluded to above, the sheets forming the substrate of thepanel may themselves be colored with pigments or dyes by introducingcolor to the raw material during the process of sheet manufacture. Hereagain, economies of scale apply, requiring the purchaser to purchasehigh volumes of colored sheets to obtain favorable pricing or to payextremely high prices for small quantities of custom colors.

As introduced earlier, there are a number of conventional mechanismsthat involve the use of laminated translucent resin panels with adecorative image layer with or without a laminating enhancing layer. Insuch cases, the decorative image layer is a printed or colored filmlayer wherein at least one of the film layer's surfaces is colored orhas an image printed thereon. In addition, the decorative image layeronly occurs between outer layers. Moreover, a laminating enhancing layermay be a required element to ensure adhesion of the various dissimilarlayers and to facilitate removal of air from between them. Incorporatinga laminating enhancing layer not only increases the processing steps andmaterials required, but also, such additional inputs can increase thepotential occurrence of manufacturing defects or contamination withinthe laminate. Because the laminating enhancing layer is non-homogeneous,it typically must be carefully tested and applied to ensure that propercoverage is attained for bonding to occur. Such conventional mechanismsuse a backing layer, which can overcome the increased level of defectscaused by the additional processing requirements, but, in the process,further increase the processing requirements. Furthermore, the backinglayer may or may not be of optical quality, and could reduce thetransparency or translucency, or both, of the resulting panel.

There are still other conventional mechanisms, which use colored filmsproduced from polyvinyl butyral (“PVB”) for use in glass lamination.According to such mechanisms, the colored PVB layer is used as atie-layer to facilitate lamination of multiple glass layers. Suchmechanisms, however, are usually specifically directed toward laminatedglass compositions.

In addition, colored PVB films, while necessary in the laminated glasscomposition, may contain plasticizers, which may not be compatible withcertain thermoplastics such as the copolyester known as PETG, (i.e.,polyethylene-co-cyclohexane 1,4-dimethanol terephthalate),polycarbonate, or acrylic (e.g., polymethyl methacrylate, or PMMA).Furthermore, PVB tends to require special handling and storageconditions including refrigeration. Such requirements can add expense tothe use of PVB in laminations. Also, plasticizers used in PVB are knownto craze polycarbonate when used in laminations with polycarbonate.

Ethyl vinyl acetate (EVA) films are known to provide good bondingcharacteristics for laminated glass structures. Such films are availablein a variety of colors from such companies as Sekesui; however, suchfilms are not ideal for use on the surface of panels due to the factthat they attract dirt and debris, making them difficult to use. Thesurface tends to be very sticky and has a low surface roughness, whichoften requires that a vacuum be used to remove air during lamination.Further, EVA has a limitation if used to construct interiorarchitectural paneling applications due to its relatively highflammability.

As noted above, an inherent challenge in manufacturing laminate panelsis avoidance of the tendency of the panels to retain air between thelayers unless preventative measures are taken to remove the air.Examples of methods used in the art for this purpose include the use ofa laminating enhancing layer and/or vacuum bagging, and using anautoclave to remove the air. Use of laminating enhancing layers and/orvacuum bagging, however, requires additional lay-up and processing stepsand materials, all of which increase expense.

BRIEF SUMMARY OF THE INVENTION

Implementations of the present invention include systems, methods, andapparatus related to a translucent and/or transparent polymer-basedpanel system that incorporates multiple colored layers. The multiplecolored layers, in turn, enable manipulation of color, transparency orlight transmission of the finished panel system. Implementations of thepresent invention also related to the construction of such panels toavoid the capture and retention of air within the panels through the useof textured surfaces at the lamination interfaces. Furtherimplementations of the present invention relate to the application of asubstantially uniform texture to a panel constructed according to thepresent invention. Accordingly, implementations of the present inventionaddress a number of deficiencies and limitations in conventionalcommercial architectural and lighting panel systems.

For example, a thermoplastic structure in accordance withimplementations of the present invention can include a substantiallytransparent polymer substrate and one or more colored film layerslaminated thereto. The colored film layers can be laminated to thepolymer substrate with the use of heat and pressure. Additionally, thecolored film layers can impart color to the entire structure.Furthermore, in at least one implementation, the polymer substrate issubstantially thicker than the colored film layers.

In addition, a thermoplastic structure in accordance with animplementation of the present invention can include one or moresubstantially transparent polymer substrates and one or more film layersadapted for fusion thereto. In this case, each of the film layers has asurface roughness that is substantially greater than a surface roughnessof the one or more substrates. The surface roughness of the film layersreduces incidences of air-entrapment between the film layers and thesubstrates during manufacture of the structure.

Moreover, a system for creating a textured, thermoplastic structure inaccordance with the present invention can include a resin panel assemblythat has a resin substrate having a front surface and a back surface,one or more colored films to be laminated to at least one of the frontsurface and the back surface of the resin substrate, and one or moretextured rollers configured to provide texture to one or more articlesof the resin panel assembly. In one implementation of the system, eachof the one or more textures rollers has a substantiallyuniformly-textured exterior shell for providing texture to the resinpanel. In addition, the one or more textured rollers can be applied tothe one or more articles simultaneously or sequentially.

Additional features and advantages of exemplary implementations of theinvention will be set forth in the description which follows, and inpart will be obvious from the description, or may be learned by thepractice of such exemplary implementations. The features and advantagesof such implementations may be realized and obtained by means of theinstruments and combinations particularly pointed out in the appendedclaims. These and other features will become more fully apparent fromthe following description and appended claims, or may be learned by thepractice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otheradvantages and features of the invention can be obtained, a moreparticular description of the invention briefly described above will berendered by reference to specific embodiments thereof which areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the invention will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings in which:

FIG. 1 illustrates a side, cross-sectional view of a panel assembly inaccordance with one implementation of the present invention, detailingtexture distributed over both bonding surfaces;

FIG. 2 illustrates a lay-up assembly of an article in accordance with animplementation of the present invention, which is configured with acolored film on each side of the substrate;

FIG. 3 illustrates an exploded, side view of a lay-up assembly withthree films positioned on one side of the substrate;

FIG. 4 illustrates an assembly configured with a colored film layerbetween two sheets of substrate;

FIG. 5 illustrates an assembly configured with a colored film layercomprising two colored films between two sheets of substrate;

FIG. 6 illustrates a lay-up assembly comprising a plurality of filmspositioned on one side of a substrate, which is configured to increasethe resident depth of the colored films;

FIG. 7A illustrates a panel assembly configured with a colored film oneach side of a substrate, and a texture roller used to apply texture tothe panel assembly;

FIG. 7B illustrates the panel assembly of FIG. 7A, with the coloredfilms bonded to the substrate, and prior to the texture roller applyingtexture to the panel assembly;

FIG. 7C illustrates the panel assembly of FIG. 7B after the textureroller has applied texture to the panel assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Implementations of the present invention include systems, methods, andapparatus related to a translucent and/or transparent polymer-basedpanel system that incorporates multiple colored layers. The multiplecolored layers, in turn, enable manipulation of color, transparency orlight transmission of the finished panel system. Implementations of thepresent invention also relate to the construction of such panels toavoid the capture and retention of air within the panels through the useof textured surfaces at the lamination interfaces. Furtherimplementations of the present invention relate to the application of asubstantially uniform texture to a panel constructed according to thepresent invention.

Accordingly, implementations of the present invention allow designers(e.g., architects, manufacturers, assemblers, etc.) to create highquality, aesthetically pleasing colored panel assemblies withoutrequiring numerous complex process steps. In particular, panelassemblies constructed according to implementations of the presentinvention have few, if any, pockets of trapped air, which can lead tounsightly blemishes and diminished structural integrity of a finishedpanel assembly. Additionally, through selection of the number and colorof film layers used to create a panel assembly according toimplementations of the present invention, the color, light transmission,and color durability properties of the panel assembly can be readilycustomized to create a colored panel assembly tailored for a specificapplication or product design. Furthermore, the panel assemblies can beformed with a substantially uniform surface texture that does not tendto cause streaking of the panel assembly color. The following examplesdescribe some example implementations of the present invention forcreating such high quality, aesthetically pleasing colored panelassemblies.

Example 1 Textured Vs. Non-Textured Films

Producing fused laminate panels in open-air lamination processes canresult in panels that exhibit air-entrapment, or bubbles, particularlyduring the fusion process when the interfacing layers of the panel justbegin to fuse. Air movement restriction occurs when any layer-to-layerinterface is fused together and subsequently blocks movement of air fromthe inner surface of the panel to the outer perimeters. Air movementrestriction often occurs particularly during open-air laminationsinvolving smooth or polished surfaces. By increasing the surfaceroughness of one or both interfaces to be fused in a laminated panelassembly, the amount of air trapped within a finished panel can bedramatically reduced, if not eliminated. Trapped air is not only deemedunsightly in an aesthetic panel, but it also can create interstitialsites that act as notches within the panel structure. Such notchesresult in potential breakage sites and can be detrimental to thephysical performance of panels when used in structural applications.

Typical open-air laminations are produced with single thin-film layerswithout laminating enhancing layers (LEL) or vacuum assist. Thethin-film layers typically have surface average roughness (R_(a)) valueson a first and/or second surface, as measured with a POCKET SURFPORTABLE SURFACE ROUGHNESS GAUGE from MAHR FEDERAL INC., in the range of15-20μ inches or less. Such laminations often result in finished sheetswith significant air entrapment.

By increasing the surface roughness of the first and/or second surfaceof a thin-film layer (or multiple thin-film layers) in a laminated panelstructure produced in open-air presses, it is found that the occurrenceof air entrapment is significantly reduced as compared to laminatedpanel structures formed with thin-film layers having surface R_(a)values in the range of 15-20μ inches or less. By way of example,multi-layer film panels, 4′×8′ in dimension, were prepared with aheated-plate, open-air lamination press without the assistance oflaminating enhancing layers or vacuum bagging. The structures consistedof film thicknesses ranging from 10 to 20 mils, and were assembled inconjunction with substrates of differing thicknesses. All the filmspossessed surface R_(a) values greater than 50μ inches on both surfaces.The structures were fixed in place with steel plates and subjected tosufficient heat and pressure required to fuse the films to thesubstrates.

FIG. 1 illustrates an exploded side view of a panel assembly 110 formedwith a substrate and a film having the surface R_(a) values as describedabove. Specifically, panel assembly 110 is formed with a substrate 112and a film 114. Film 114 has a surface 116 having a surface R_(a) valuegreater than 50μ inches. In the illustrated embodiment, substrate 112has a surface 118 with a surface R_(a) value less than 10μ inches. Thus,at least one exemplary panel assembly 110 comprises one or more films114 have a surface roughness that is greater than 20μ inches, and one ormore substrates 112 with a surface roughness that is less than 20μinches.

By way of explanation, and as understood more fully herein, any or allof the resin components in the thermoplastic substrate can comprise anynumber of different resin materials, and/or combinations thereof. In oneimplementation, for example, the film(s) 114 and substrate(s) 112 cancomprise any one or more of polycarbonate materials, polyester materials(including copolyester materials), acrylic materials, and/orcombinations thereof. For the purposes of this specification and claims,a polyester material refers to any one or more of PBT, PET, PETG, orPCTG, and combinations thereof. In addition, an “acrylic” materialrefers to PMMA or the like, whether in extruded form, or created throughcontinuous casting, or mold-casting processes, and further includesimpact-modified acrylic.

FIGS. 2 and 3 illustrate lay-ups of multi-layer film panel assembliesconstructed according to at least one implementation of the presentinvention. In particular, FIG. 2 illustrates a panel assembly 120comprising a sheet (e.g., PETG) substrate 122 with PETG films 124 and126 positioned on opposing sides of the PETG sheet substrate 122 forfusion thereto. Although not illustrated in FIG. 2, each of films 124and 126 has opposing surfaces with surface R_(a) values greater than 50μinches, and substrate 122 has opposing surfaces with surface R_(a) valueless than 10μ inches.

While FIG. 2 illustrates two films positioned on opposing sides of asubstrate, it will be appreciated that panels can be constructed in avariety of configurations. For example, a panel assembly 130 can beformed with multiple films 132, 134, and 136 fused to one or more sidesof a substrate 138, as illustrated in FIG. 3. Alternatively, oradditionally, one or more films can be fused between one or moresubstrates.

For example, FIG. 4 illustrates a panel assembly 140 comprising two PETGsheet substrates 142 and 144 with a film 146 disposed therebetween. Morespecifically, film 146 is laid between a first side surface of substrate142 and a first side surface of substrate 144. In this manner, film 146can be fused between opposing substrates 142 and 144. While notillustrated in FIG. 4, film 146 typically has surface R_(a) valuesgreater than 50μ inches on opposing surfaces, and substrates 142 and 144each has at least one surface with a surface R_(a) value less than 10μinches. Similarly, FIG. 5 illustrates a panel assembly 150 with twofilms 156 and 158 positioned next to one another and disposed betweentwo opposing substrates 152 and 154.

Table 1 below provides further details of the panel assemblyconstructions illustrated in FIGS. 2 and 4, and the resulting qualityand aesthetic appearance following lamination.

TABLE 1 Translucent Thermoplastic Panel Constructs of Films with VariousAverage Surface Roughnesses. Panel Layer 1 Layer 2 Layer 3 Result 10.020″ PETG dual 0.090″ 0.020″ PETG dual All sided texture film PETGsheet sided texture film areas of R_(a1) = 62μ in., R_(a1-2) < 10μR_(a1) = 62μ in., panel R_(a2) = 64μ in. in. R_(a2) = 64μ in. free ofair 2 0.060″ PETG sheet 0.010″ 0.060″ PETG sheet All R_(a) < 10μ in.PETG dual R_(a) < 10μ in. areas of sided texture panel film freeR_(a1-2) > of air 250μ in. R_(a1)—indicates average roughness on firstsurface. R_(a2)—indicates average roughness on second surface.R_(a1-2)—indicates average roughness on first and second surfaceidentical in measure.

Example 2 Non-Homogeneous Lay-Up

A key benefit of the present invention is the ability to combine amultitude of thermoplastic film and substrate materials together toyield a finished and aesthetically pleasing structure. Any sheetsubstrate and colored film combination where the joining layers possesssufficient miscibility when combined via fusion at elevated temperaturescan be utilized for a panel system capable of multivariate colors. Sucheffective lamination may occur without a laminating enhancing layer orvacuum assistance so long as the highest glass-transition temperature(T_(g)) of the heterogeneous materials is exceeded during the laminationprocess, and the materials are sufficiently miscible so as not to resultin hazing or insufficient bonding.

For example, in one implementation, multiple panel structures werecreated by laminating one or more PETG sheets to one or more PVC (i.e.,polyvinyl chloride) films to produce 12″×12″ panel assemblies in anopen-air lamination mechanical press. During the laminating process, thepress operation averaged 265° F., under pressure of 40 psi, with a heatsoak time of 11 minutes. The particular combinations of PETG sheets andPVC films used to create three structures according to thisimplementation, identified as structures A, B, and C, respectively, aredetailed below.

Structure A was formed using a first layer of PVC film and a secondlayer of a PETG sheet. The first layer of PVC film was a translucent,non-textured, orange PVC film having a 0.010″ thickness. The secondlayer was a 0.118″ thick, clear, non-textured PETG sheet. The two layersof structure A were laminated together according to the presentimplementation of the invention.

Structure B was created by laminating five layers of thermoplastic filmand substrate materials together according to the present implementationof the invention. The first layer comprised a 0.060″ thick, clear,non-textured PETG sheet. The second layer comprised a translucent,non-textured, red PVC film with a thickness of 0.010″. The third layercomprised another 0.060″ thick, clear, non-textured PETG sheet. Thefourth layer comprised another translucent, non-textured, red PVC filmwith a thickness of 0.010″. Finally, the fifth layer comprised a 0.060″thick, clear, non-textured PETG sheet. In other words, structure B wasformed with three 0.060″ thick, clear, non-textured PETG sheetsseparated by 0.010″ thick, translucent, non-textured, red PVC films.

Similarly, structure C was created by laminating five layers ofthermoplastic film and substrate materials together according to thepresent implementation of the invention. The first layer comprised a0.060″ thick, clear, non-textured PETG sheet. The second layer compriseda translucent, non-textured, red PVC film with a thickness of 0.010″.The third layer comprised a 0.118″ thick, clear, non-textured PETGsheet. The fourth layer comprised a translucent, non-textured, orangePVC film with a thickness of 0.010″. Finally, the fifth layer compriseda 0.060″ thick, clear, non-textured, PETG sheet.

For all three structures, A-C, no panel exhibited shadows or air gapswithin the panel that would exemplify delamination or insufficientbonding. Further, each of structures A-C were produced with twodissimilar but relatively miscible materials, PVC and PETG, and wereadequately fused together at elevated temperatures above the respectivematerial's T_(g) (PVC film T_(g)˜185° F. and PETG T_(g)˜176° F.) withoutthe assistance of a laminating enhancing layer or vacuum.

In a second example of dissimilar resin materials being laminated toform a single panel structure, a polycarbonate sheet was fused to a PETGfilm to produce a 12″×12″ panel in an open-air lamination mechanicalpress. The press operation averaged 330° F., under pressure of 40 psi,with a heat soak time of 15 minutes. The particular polycarbonate sheetand PETG film combinations used to create two of the structuresaccording to this implementation are identified as structures D and E,respectively, and are detailed below.

Structure D was formed using a first layer of PETG film and a secondlayer of a polycarbonate sheet. The PETG film was a translucent, 2-sidedtextured, blue PETG film with a 0.010″ thickness. The second layer ofpolycarbonate sheet was a 0.236″ thick, clear, non-texturedPolycarbonate sheet. Structure D was created by laminating the twolayers together according to implementations of the present invention.

Likewise, structure E was formed using a first layer of PETG film and asecond layer of a polycarbonate sheet. The PETG film was a translucent,2-sided textured, blue PETG film with a 0.010″ thickness. The secondlayer of the polycarbonate sheet was a 0.118″ thick, clear, non-texturedpolycarbonate sheet. The two layers of structure E were laminatedtogether according to the present implementation of the invention.

Although polycarbonate and PETG are not considered “thermallycompatible” due to the wide disparity in T_(g) between the materials(PETG film T_(g)˜176° F. and Polycarbonate T_(g)˜300° F.), thepolycarbonate and PETG layers of each of structures D and E werecombined to form aesthetically pleasing laminated panel assemblies withgood adhesion, and no evidence of insufficient bonding or distortion.

In a final example of dissimilar resin materials being laminated toproduce a single panel structure, identified as structure F, a PETGsheet (T_(g)˜176° F.) was laminated to three PCTG (i.e., glycol modifiedpoly-cyclohexylene-dimethylene terephthalate) films (T_(g)˜187° F.) toproduce 12″×12″ panel assemblies in an open-air lamination mechanicalpress. The press operation averaged 265° F., under pressure of 40 psi,with a heat soak time of 10 minutes. The PETG sheet used to createstructure F comprised a 0.500″ thick, clear, non-textured PETG sheet.Each of the three PCTG films used to form structure F comprised atranslucent, white, single-side textured PCTG film with a 0.010″thickness. In forming structure F, the three PCTG film layers werelaminated to one side of the PETG sheet.

As with the previous examples, structure F, though produced withmultiple PCTG films and a PETG sheet, was sufficiently bonded with noevidence of delamination of the PCTG films from the PETG sheet.

Example 3 Multivariate Coloring of Panel Assemblies

Different colored films, ranging from 0.001″ to 0.030″ in thickness,more preferably in a range of 0.005″ to 0.020″ in thickness, and mostpreferably from 0.010″ to 0.015″ in total thickness, can be thermallycombined to make a single, uniformly colored panel assembly. Thethermoplastic film layers may be positioned separately on the outermostsurfaces of any clear thermoplastic substrate that is miscible with thethermoplastic film of any gauge, so long as the substrate is clear,transparent and has a clear or neutral color. Or, the thermoplasticfilms may be positioned conjointly on a single surface of the samesubstrate without significant change to the overall surface color of thepanel assembly.

Combination through lamination or adhesion of such film layers ofdiffering colors creates a uniform colored panel assembly that is acomposite color of the individual film colors used to construct thepanel assembly. Furthermore, the color ordering of two or more coloredfilms is not important as the color and hue of the panel remains thesame throughout the finished panel regardless of viewing direction andordering of the films on or within the substrate. For example, FIG. 6illustrates a panel assembly 160 that is configured with a substrate162, and multiple films 164, 166, 168, 170, and 172 to be fused thereto.In the illustrated example in FIG. 6, the multiple films 164, 166, 168,170, and 172 are configured to be fused to the same surface of substrate162, and comprise three colored films 164, 168, and 172, and twotransparent films 166 and 170 positioned between colored films 164, 168,and 172. As discussed herein, however, multiple films and/or substratescan be ordered in any manner, or left out entirely, to alter the color,hue, color durability, or other properties of the panel assembly asdesired.

In one implementation, laminated thermoplastic panels were produced fromcolored PETG and PCTG films possessing a total thickness of 0.010″. Allfilms were textured on the front and back surface with a surface R_(a)value of 65μ inches as measured with a POCKET SURF PORTABLE SURFACEROUGHNESS GAUGE from MAHR FEDERAL INC. The optical properties of thesefilms were measured with a HUNTERLAB COLORQUEST XE spectrophotometerwith the TTRANS scanning method. The color measures of each base filmwere measured and quantified with the respective L*, a*, b*, haze andpercent light-transmission values as reported from the spectrophotometermeasurements. Table 2 lists the color and optic measurements andprovides a description of each film layer used in these examples.

TABLE 2 Associated Color and Optics Measures of Experimental ColoredFilms. % Light Color Name (description) L* a* b* Haze TransmissionPOMEGRANATE 52.05 49.82 14.62 77.68 20.19 (dull red PETG film) ALLURE55.44 −1.69 −34.76 80.25 23.36 (deep blue PETG film) LAWN 84.37 −29.4138.47 79.24 64.78 (emerald green PETG film) WHITE 86.96 −10.85 41.0466.84 65.42 (translucent white PCTG film)

Laminate structures of two different gauges were produced with filmslisted by the color names described in Table 2 to ascertain theaesthetic affect that orientation of the films has on the overall panel.Table 3 provides detailed lay-ups of the several combinations of color,gauge and color-film-layer positioning with respect to the panels.

TABLE 3 Panel Lay-ups for Directional Color Measurement ComparisonExhibits. Sample Surface 1 Surface 4 Number (front) Surface 2 Surface 3(back) A 0.030″ 0.010″ 0.010″ 0.030″ Clear ALLURE POMEGRANATE Clear PETGfilm PETG film PETG film PETG film B 0.010″ 0.060″ 0.010″ NA ALLUREClear POMEGRANATE PETG film PETG sheet PETG film C 0.500″ 0.010″ 0.010″0.500″ Clear ALLURE POMEGRANATE Clear PETG sheet PETG film PETG filmPETG sheet D 0.010″ 0.500″ 0.500″ 0.010″ ALLURE Clear Clear POMEGRANATEPETG film PETG sheet PETG sheet PETG film E 0.010″ 0.060″ 0.010″ NAPOMEGRANATE Clear LAWN PETG film PETG sheet PETG film F 0.010″ 0.500″0.500″ 0.010″ POMEGRANATE Clear Clear LAWN PETG film PETG sheet PETGsheet PETG film

The panel assemblies in Table 3 above were laminated in a mechanicalheat press in 4″×4″ plaques, and then measured for color with aHUNTERLAB COLORQUEST XE spectrophotometer (TTRANS method). Each samplewas measured from both the front and back surfaces facing thespectrophotometer light source to compare for directional differences.The results are depicted in Table 4.

TABLE 4 Directional Measures of Dissimilar Color Film Layers Laminatedas a Single Assembly. Sample Number Measurement Direction L* a* b* AFront 31.26 36.14 −12.79 A Back 31.37 36.15 −12.88 B Front 31.74 35.21−14.05 B Back 31.78 35.14 −14.18 C Front 33.18 33.73 −11.57 C Back 34.0733.15 −12.03 D Front 29.62 34.34 −11.73 D Back 30.25 34.43 −11.62 EFront 45.56 29.99 36.44 E Back 46.22 29.77 36.03 F Front 42.15 28.3634.57 F Back 41.88 27.85 33.79

As shown in Table 4, all sample color measurements, regardless of color,gauge or film positioning within a sample construct show significantlyidentical L*, and b* color values when measured from the front and theback surfaces of the sample constructs. These measurements confirm thatthe color is uniform throughout the panel, despite opposing colors beingon opposing surfaces of a given panel assembly.

Example 4 Manipulation of Color Intensity with a Multiplicity of Layers

Implementations of the present invention further comprise controllingthe color intensity of a panel assembly with the addition of multiplefilm layers of the same color. To exemplify the relative intensityeffect that can be achieved with the addition of multiple colored filmlayers in a laminated panel, samples were produced with colored films asdetailed in Table 2. Such layering enables end users to control theintensity of color of finished panels through simple addition of samecolor layers. In the case of this example, sample structures wereproduced from PETG films and sheets with an open-air lamination pressunder conditions sufficient for bonding materials together without theuse of a laminating enhancing layer (˜250° F. for 10 minutes at 40 psi).The configurations of colored films and sheets utilized to produce theexample structures are listed in Table 5 below. The data presented inTable 6 is representative of the resultant color of the structures asmeasured with a HUNTERLAB COLORQUEST XE spectrophotometer.

TABLE 5 Panel Configurations Produced with Multiple Homogeneous ColorLayers Sample Surface 1 Surface 5 Number (front) Surface 2 Surface 3Surface 4 (back) G 0.500″ 0.010″ 0.500″ NA NA Clear POMEGRANATE ClearPETG sheet PETG film PETG sheet H 0.500″ 0.010″ 0.010″ 0.500″ NA ClearPOMEGRANATE POMEGRANATE Clear PETG sheet PETG film PETG film PETG sheetI 0.500″ 0.010″ 0.010″ 0.010″ 0.500″ Clear POMEGRANATE POMEGRANATEPOMEGRANATE Clear PETG sheet PETG film PETG film PETG film PETG J 0.010″0.500″ NA NA NA LAWN Clear PETG film PETG sheet K 0.010″ 0.010″ 0.500″NA NA LAWN LAWN Clear PETG film PETG film PETG L 0.010″ 0.010″ 0.010″0.500″ NA LAWN LAWN LAWN Clear PETG film PETG film PETG film PETG sheet

TABLE 6 Resultant Color Measures of Panels Produced with Multiple ColorLayers. Light Sample L* a* b* Transmission G 56.56 44.5 10.76 24.47 H37.67 52.87 25.17 9.91 I 28.20 49.26 33.46 5.45 J 82.49 −34.42 37.8961.2 K 76.54 −44.2 51.15 50.77 L 70.34 −52.92 56.72 41.23

As is shown with the data in Table 6, increasing the film layers has apredictable effect on L* and light transmission. That is, as the numberof color film layers increases, the apparent “darkness” (ascharacterized by decreasing L* and decreasing light transmission) of thepanel increases accordingly. While there is movement in the a* (red togreen axis) and b* (blue to yellow axis) values of the samples, therelative hue of the color stays intact upon visual inspection, and thecolors show an increase in intensity in accordance with the decrease inlight transmission.

Example 5 Manipulation of Light Transmission and Diffusion Performance

Implementations of the present invention further comprise controllingthe panel optical properties with the addition of translucent “WHITE”film layers. Such control of light transmission and diffusion propertiesis often important in the design of artificial and day-lighting systemswith respect to spreading light across a panel and creating a desiredlighting effect.

To demonstrate the effects of varying light transmission, 4″×4″ samplepanels were assembled and fused as described by the configurationslisted in Table 7. Lamination was conducted in an open-air laminationpress at approximately 265° F. for 10 minutes at 40 psi, which canconstitute appropriate bonding conditions for laminating one or morePCTG films to a PETG sheet. The base “WHITE” film was produced from PCTGand is characterized in Table 2.

TABLE 7 Panel Configurations Produced with Multiple White Color Layers.Surface 1 Surface 4 Sample (front) Surface 2 Surface 3 (back) M 0.010″WHITE 0.060″ Clear NA NA PCTG film PETG sheet N 0.010″ WHITE 0.010″WHITE 0.060″ Clear NA PCTG film PCTG film PETG sheet O 0.010″ WHITE0.010″ WHITE 0.010″ WHITE 0.060″ Clear PCTG film PCTG film PCTG filmPETG sheet

The color, light transmission and haze responses, as measured with aHUNTERLAB COLORQUEST XE spectrophotometer (TTRANS setting), of thesamples listed in Table 7 are represented in Table 8.

TABLE 8 Color and Optical Measurements of Panels with Multiple Layers ofTranslucent White Film. Sample L* A* B* Haze Light Transmission M 81.562.81 −2.53 90.84 59.48 N 74.58 3.04 −2.59 97.80 47.61 O 69.67 3.20 −3.3399.08 40.28

Similar to the ability to increase panel color intensity with theaddition of multiple layers of colored films, increasing the number oftranslucent “WHITE” film layers has a significant effect on the overalllight transmission and diffusion (as characterized by haze) propertiesthat are exhibited in a translucent laminated panel. Further, theresults in Table 8 also point to a consistency of color hue that ischaracterized by the small differences among the measured a* and b*values of samples produced with one, two, and three layers oftranslucent “WHITE” film.

The practice of the present invention lends itself well as a tool fordesigners and specifiers of interior lighting and panel systems. Havingthe ability to manipulate the light transmission and diffusion (haze)properties of a panel allows one to control the amount of lightscattering, and the ultimate aesthetic lighting effect that occurs atthe panel surface. Increasing the haze value, by increasing the numberof translucent “WHITE” layers, allows designers to manipulate thetransparency of a lighting and panel system to achieve the desiredvisual effects in a lighting application, regardless if the light sourcein the application is from artificial light sources (incandescent,fluorescent, LED, halogen, etc.) or natural daylight.

An added feature can be introduced with one or multiple translucent“WHITE” film layers laminated in conjunction with colored film layers.Table 9 demonstrates that the change in the light transmission and thediffusion characteristics created by translucent “WHITE” film layers ina laminated panel can be utilized in conjunction with panels thatcontain colored film layers. When translucent “WHITE” films are combinedwith colored film layers, one has the ability to modify the lighttransmission and the diffusion characteristics of a panel with littleeffect on the overall panel color.

In the example case represented in Table 9, a first panel of 1/32″nominal thickness was constructed in an open-air lamination press with a0.010″ thick first surface layer of “ALLURE” blue film (as described inTable 2) laminated to a 0.060″ thick layer of clear PETG sheet. A secondpanel was constructed with the same 0.010″ thick “ALLURE” blue film onthe first surface and a second layer of 0.010″ “WHITE” PCTG film (asdescribed in Table 2) laminated to a 0.060″ thick layer of clear PETGsheet. The data in Table 9 shows that the incorporation of a “WHITE”translucent film layer, even with a color, has a dramatic effect on thehaze and light transmission of the panel. Despite the large change inlight transmission and haze values, the “WHITE” translucent film layerimparts only a slight difference to the overall color hue (asrepresented by the a* and the b* values) between the color-only sampleand the sample with a color layer and a “WHITE” diffuser layer.

TABLE 9 Fused Colored Panels Produced With and Without a TranslucentWhite Diffusing Layer. Light Panel lay-up L* a* b* Haze TransmissionBlue + Clear 63.63 −3.74 −31.26 8.63 32.34 Blue + WHITE + Clear 48.33−0.14 −26.42 82.71 17.06

Example 6 Laminated Panels with Colored Films Used in Combination withNeutral Fabrics

Additional implementations of the present invention include the abilityto add color to neutral (clear or white) fabric inserts through thefusion of colored film layers to the fabric layers. To this end, samples(4″×4″) of such laminations were produced with fabrics, and with coloredfilms combined with fabrics, in an open-air lamination press. Theconfigurations of the samples produced are described in Table 10.Laminated panels with only fabric inserts were included for the purposeof comparison to laminated panels containing both fabrics and coloredfilm layers. The “LAWN” color identified in Table 10 is the samematerial as previously characterized in Table 2.

TABLE 10 Constructs of Panels Containing Fabrics and Fabrics withColored Film Layers Surface 1 Surface 5 Sample (front) Surface 2 Surface3 Surface 4 (back) P 0.236″ Clear Clear 0.236″ Clear NA NA PETG sheetSheer fabric PETG sheet Q 0.236″ Clear White 0.236″ Clear NA NA PETGsheet Voile fabric PETG sheet R 0.236″ Clear White 0.236″ Clear NA NAPETG sheet Taffeta Fabric PETG sheet S 0.236″ Clear 0.010″ LAWN Clear0.010″ LAWN 0.236″ Clear PETG sheet PETG film Sheer fabric PETG filmPETG sheet T 0.236″ Clear 0.010″ LAWN White 0.010″ LAWN 0.236″ ClearPETG sheet PETG film Voile fabric PETG film PETG sheet U 0.236″ Clear0.010″ LAWN White 0.010″ LAWN 0.236″ Clear PETG sheet PETG film Taffetafabric PETG film PETG sheet V 0.010″ LAWN 0.236″ Clear White 0.236″Clear 0.010″ LAWN PETG film PETG sheet Voile fabric PETG sheet PETG film

The resultant panels were measured for color and optical response in aHUNTERLAB COLORSCAN XE spectrophotometer (TTRANS setting). Themeasurement results are listed in Table 11.

TABLE 11 Color and Optical Measurements of Laminated Panels ContainingFabrics With and Without Color Film Layers. Sample L* a* b* Haze LightTransmission P 91.08 0.07 0.78 5.62 78.66 Q 79.13 0.51 1.04 17.65 55.15R 49.54 1.47 0.62 82.95 18.03 S 74.65 −42.94 50.45 24.31 47.73 T 63.79−37.69 45.52 37.84 32.54 U 33.5 −25.43 30.13 97.81 7.77 V 63.94 −37.6344.39 24.11 48.76

The data in Table 11 exemplifies the aesthetic differences between thesheer, voile and taffeta fabrics in terms of color, haze and lighttransmission. These differences create unique panel aesthetics andlighting effects when laminated into single panel constructions and usedin applications that are either lighted or serve as a light-diffusingmedium of daylight or artificial lighting. Comparison of samples P to S,Q to T, and S to V show the effect that the color film layers impartonto the fabric layer, and the structure as a whole, laminated into asingle panel.

Of significance is a comparison of sample S from Table 11, which isproduced with 2 layers of the “LAWN” color film in contact with a whitevoile fabric, with sample K from Table 6, which is the same totalthickness and also produced with two layers of the same “LAWN” colorfilm. The resultant panel colors as characterized by the measured L*, a*and b* values are virtually identical with the only difference being areduction in the light transmission of sample S, which is due to thefabric. Such a result demonstrates that the color of the film doestranslate to the fabric to create the effect of a pre-colored fabric.

Samples T and V of Table 11 further demonstrate that the placement ofthe colored film layer, or layers, with respect to the position offabric in the laminated panel structure has no effect on the overallmeasured color values obtained from a laminated panel. This resultdemonstrates that the colored film layers do not have to be in directcontact with the fabric layer to impart a consistent color appearance tothe fabric.

In addition to creating a colored panel as described herein, amanufacturer can apply a texture to any one or more of the films,substrates, and/or film/substrate laminate combinations for any numberof purposes. In at least one implementation, and as previouslydescribed, the manufacturer can apply texture to one or more filmsand/or one or more substrates before lamination in order to ensureappropriate air removal between the film(s) and substrate(s) duringlamination. In addition, the manufacturer can apply texture to asubstrate/film laminate combination for a variety of aesthetic purposes(e.g., better diffusion, avoidance of color streaking, etc.)

In conventional cases, a manufacturer will typically provide texture toa panel by including a texture paper as one of the various layers in theforming/laminating process. For example, in addition to the layers shownin FIG. 4, a manufacturer might further include a texture paper layer ona surface of substrate 142 and/or 144; or, with respect to the layersshown in FIG. 1, the manufacturer might further include the texturepaper layer on top of the film layer 114, which is on top of thesubstrate. In some cases, however, depending on one or more of the filmlayers and the granularity of the texture paper, this sort ofapplication of texture can result in uneven air removal in thefunctional sense, or uneven streaking of colors in the aesthetic sense.This tends to occur particularly if the manufacturer subsequentlylaminates the panel with yet another color film layer.

With respect to the color/aesthetic aspect, one reason for suchstreaking may include the notion that the texture granules on thetexture paper are somewhat randomly aligned, which means that, in somecases, valleys and peaks can form that provide some of the color filminks a conduit for streaking during lamination. A similar effect can beobserved with respect to using texturing in order to remove air frombetween film and/or substrate layers. That is, random or less-than-idealdistribution of texture granules, can result in texturing of the filmand/or resin substrates that entraps air in the final panel, and thusresults in a final panel with reduced aesthetic qualities.

Accordingly, implementations of the present invention further includeone or more apparatus and methods for applying texture to films,substrates, and/or completed panels while minimizing or outrighteliminating any potential for air entrapment, and/or color streaking insuch panels. This can be done at least in part by providing a much moreuniform distribution of texture granules on a texture applicator. In atleast one implementation, applying this distribution can be done atleast in part by using a textured roller to apply texture to a coloredfilm, substrate, and/or completed panel, whereby the textured rollerimparts a highly uniform texture. The manufacturer can then apply thetextured film to the substrate (which may also be textured using similaror identical mechanisms). During lamination, as described herein, theuniformly-applied texture one or all of the given surfaces can thenprovide for sufficient air removal between surfaces on the one hand,and/or avoid any color streaking on the other hand.

Along these lines, FIGS. 7A-7C illustrate various schematic diagrams forapplying texture in accordance with an additional or alternativeimplementation of the present invention using a textured roller. In theillustrated case, FIGS. 7A-7C show components in a process for producinga finished lamination product for aesthetic effects. Such illustration,however, is primarily by way of convenience, as the mechanism forlamination is essentially the same whether providing texture to anindividual film or an individual substrate prior to lamination, such asto achieve improved air removal effects.

In either case, a texture-applying roller 180 (or textured roller) cancomprise a cylinder having a double wall, spiral baffle using mild steelconstruction. In such a case, this roller can further comprise an outershell 182 produced from 4140 stainless steel that has been hardened to52-54 Rc (“Rockwell Hardness.”) In at least one implementation, theroller size can be about a 16″ diameter with a 66″ face, and can beprepared with a plurality of different textures. In at least oneimplementation, for example, the roller is prepared (e.g., sandblastedor engraved) with a texture of having a R_(a) value of 150μ inches, and,in another implementation, the roller is prepared (e.g., sandblasted orengraved) with a texture having a R_(a) value of 250μ inches.

At least one method of applying texture, therefore, includes firstobtaining the article to be textured (e.g., the colored film, the resinsubstrate, or completed panel). If texturing a completed panel, such asillustrated in FIG. 7A, the manufacturer first prepares colored panel184 using one or more colored films 186 and 188. In particular, aspreviously described, a manufacture can form or laminate one or morecolored films to one or more surfaces of a resin substrate (e.g.,polycarbonate, acrylic, co-polyester, etc.). Of course, one willappreciate that, as also previously described, the articles (i.e., thesubstrate article and one or more color film articles) will be at leastpartially translucent. Nevertheless, FIG. 7A illustrates the substrateand films without translucence/transparency effects for purposes ofconvenience in illustration.

As shown in FIG. 7B, however, the lamination of the one or more colorfilm articles to the substrate article results in an at least partiallytranslucent article (e.g., panel 184) that bears the color (or colorcombination) presented by the applied color film layers. If the articleto be textured is simply a colored film alone, however, FIG. 7Bsimilarly can be construed as representing a colored film article or abasic resin substrate article prior to lamination. Specifically, FIG. 7Billustrates the translucency of any given article (e.g.,laminated/colored panel 184) prior to applying texture.

In either case, the texturing process begins by heating the surface ofthe panel to above the material's T_(g). The manufacturer then passesthe article (e.g., laminated/colored panel 184, or just film 186 and/or188) through the one or more textured rollers 180, which have beenchosen based on the texture or surface roughness of the given roller 180(or set of rollers). As shown in FIG. 7C, passing the given article(e.g., panel 184, or films 186 and/or 188) through the one or moretextured rollers 180 results in application of the texture (i.e., ininverted form) from the roller 180 to the panel 184 and/or film(s)186/188. Following transfer of the roller texture to the article, themanufacturer allows the textured article to cool below the T_(g) tocomplete the texturing process. If texturing the films 186/188 articlesseparately, the manufacturer can then laminate the now-textured filmarticles 186/188 to the resin substrate 184 article, as previouslydescribed herein.

On the one hand, if the manufacturer has only textured the exposed sideof the colored film (or laminated panel), the resulting product is athermoplastic panel such as shown in FIG. 7C, in which a resinthermoplastic panel comprises a textured film laminated to a base resinsubstrate 184. On the other hand, if the manufacturer has only appliedtextured to an inside surface of a film article that is placed directlyagainst the surface of the resin substrate article, the texturing shownin FIG. 7C will be less visible (or potentially invisible). One willappreciate in either case that because the roller 180 is preparedcarefully with a uniform distribution of texture granules, and becausethe roller 180 provides a continuous and repeated application of thetexture granulation, the ultimate, laminated end product is virtuallyensured to have a uniform distribution of texture thereon. This, inturn, can minimize or outright avoid any air entrapment, and/or avoidscolor streaking that could accompany application of the color film(s)(particularly subsequent color films laminated on top of the texturedsurface(s)).

As a final matter, one will appreciate that a manufacturer can applymultiple rollers to a given article in order to impart texture. With acolor film article (or non-laminated substrate article), for example,the manufacture may desire to achieve the air removal benefits oftexturing on one side of the colored film, but also achieve the benefitsof avoiding color streaking on the other side of the film article. Witha laminated panel article, the manufacturer may desire to achieve theabove-described aesthetic benefits on both sides of the finished panel.

In addition, there may be other reasons in which a manufacturer maydesire to apply multiple different rollers on the same side of thearticle to achieve still other aesthetic or performance effects.Furthermore, the manufacturer may apply texture on opposing sides of thegiven article with opposing rollers, or simply turn the article overafter application of texture on one side and then apply texture to thesecond side of the article. Accordingly, illustration of a singletextured roller to a single side of a given article is done by wayprimarily of convenience, and thus should not be construed as limiting.In any event, and as previously mentioned, the manufacturer may evenapply still additional color films on top of the textured surface(s),and further pass the article again through texturing (on top of the newcolor films).

The present invention thus may be embodied in other specific formswithout departing from its spirit or essential characteristics. Thedescribed embodiments are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes that come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

I claim:
 1. A decorative, translucent thermoplastic structure formed tohave the appearance of a unitary color diffused throughout itscomposition, the structure comprising: a transparent resin substratehaving opposing front and back surfaces separated by a thickness of0.236 inches to 1 inch, wherein the front or back surface comprises abonding surface having a first surface roughness, the thickness defininga distance of opposing side wall surfaces that are perpendicular to theopposing front and back surfaces; a translucent colored film layer thathas a bonding surface with a second surface roughness that is differentfrom the first surface roughness, wherein the bonding surface of thecolored film layer has been fused to and intermixed with the bondingsurface of the resin substrate; and a highly uniform texture applied toeach surface of the thermoplastic structure; wherein: the surfaceroughness of at least one of the bonding surfaces of the resin substrateor of the first colored film comprises an even distribution of texturegranules; and the applied texture and intermixing of the translucentcolored film layer cooperate to diffuse the color of the translucentcolored film layer throughout the thermoplastic structure, such that thethermoplastic structure displays the color of the translucent coloredfilm on all sides of the thermoplastic structure, regardless of theviewing direction.
 2. The thermoplastic structure as recited in claim 1,wherein the transparent resin substrate has a thickness of 0.500 inchesto 1 inch.
 3. The thermoplastic structure as recited in claim 1, whereinthe transparent resin substrate and the translucent colored filmcomprise the same resin material selected from the group consisting ofPVC, polyester, acrylic, polycarbonate, and combinations thereof.
 4. Thethermoplastic structure as recited in claim 1, wherein the transparentresin substrate comprises PETG, and the translucent colored filmcomprises PVC or PCTG.
 5. The thermoplastic structure as recited inclaim 1, wherein: the translucent colored film is formed from a materialselected from the group, consisting of PVC, polyester, acrylic,polycarbonate, and combinations thereof; and the transparent resinsubstrate is formed from a different material in the same group, suchthat the transparent resin substrate material is different from thetranslucent colored film material selected from the group.
 6. Thethermoplastic structure as recited in claim 1, wherein both thetransparent resin substrate and the translucent colored film comprise asurface roughness having an even distribution of texture granules. 7.The thermoplastic structure as recited in claim 1, wherein: thetransparent resin substrate and the translucent colored film layer arefused together through application of heat and pressure; and the heatapplied during the fusing process exceeds the glass-transitiontemperature (Tg) of each of the transparent resin substrate and thetranslucent colored film layer.
 8. The thermoplastic structure asrecited in claim 1, wherein the thermoplastic structure is devoid ofentrapped air or color streaking.
 9. The thermoplastic structure asrecited in claim 1, wherein the uniformly applied texture ismechanically applied.
 10. The thermoplastic structure as recited inclaim 9, wherein the uniformly applied texture is imparted via one ormore textured rollers.
 11. The thermoplastic structure as recited inclaim 1, wherein: the transparent resin substrate has a bonding surfacehaving first surface roughness; and the translucent colored film layerhas a bonding surface having a second surface roughness that isdifferent from the first surface roughness.
 12. The thermoplasticstructure as recited in claim 1, wherein: one of the transparent resinsubstrate or the translucent colored film layer has a bonding surfacethat is greater than 20μ inches; and the other of the transparent resinsubstrate or the translucent colored film layer has a bonding surfacethat is less than 20μ inches.
 13. The thermoplastic structure as recitedin claim 1, wherein the second surface roughness of the translucentcolored film is up to 25 times the first surface roughness of thetransparent resin substrate.
 14. A decorative, translucent thermoplasticstructure prepared from a plurality of dissimilar resin materials tohave the appearance of a unitary structure having a color diffusedthroughout its composition, the structure comprising: a transparentresin substrate having opposing viewing surfaces and a plurality ofadjacent edges that separate the opposing viewing surfaces by 0.236inches to 1 inch, the transparent resin substrate comprising a firstresin material; a translucent colored film made of a second resinmaterial that is dissimilar to the first resin material, but that isnevertheless miscible with the first resin material, the translucentcolored film being fused to and intermixed with the transparent resinsubstrate; and a texture having been uniformly applied to all surfacesof a completed panel comprising the fused combination of the resinsubstrate and colored film layer; wherein the uniformly applied texturecombined with the intermixing of the combined resin substrate andcolored film layer cooperate to diffuse the color of the colored filmthroughout the thermoplastic structure regardless of viewing angle oneach viewing surface, and substantially uniformly on the plurality ofadjacent edges.
 15. The thermoplastic structure as recited in claim 14,wherein the transparent resin substrate has a thickness of 0.500 inchesto 1 inch.
 16. The thermoplastic structure as recited in claim 14,wherein the transparent resin substrate comprises PETG, and thetranslucent colored film comprises PVC or PCTG.
 17. The thermoplasticstructure as recited in claim 14, wherein: the first resin material isselected from the group consisting of PVC, polyester, acrylic,polycarbonate, and combinations thereof; and the second resin materialcomprises a dissimilar resin material selected from the same group, suchthat the second resin material is dissimilar to the first resin materialselected from the group.
 18. The thermoplastic structure as recited inclaim 14, wherein both the transparent resin substrate and thetranslucent colored film comprise a surface roughness having an evendistribution of texture granules.
 19. The thermoplastic structure asrecited in claim 14, wherein: the transparent resin substrate and thetranslucent colored film layer are fused together through application ofheat and pressure; and the heat applied during the fusing processexceeds the glass-transition temperature (Tg) of each of the transparentresin substrate and the translucent colored film layer.
 20. Thethermoplastic structure as recited in claim 14, wherein thethermoplastic structure is devoid of entrapped air or color streaking.21. The thermoplastic structure as recited in claim 14, wherein theuniformly applied texture is mechanically applied.
 22. The thermoplasticstructure as recited in claim 21, wherein the uniformly applied textureis imparted via one or more textured rollers.
 23. The thermoplasticstructure as recited in claim 14, wherein: the transparent resinsubstrate has a bonding surface having first surface roughness; and thetranslucent colored film layer has a bonding surface having a secondsurface roughness that is different from the first surface roughness.24. The thermoplastic structure as recited in claim 23, wherein: one ofthe first surface roughness or the second surface roughness is greaterthan 20μ inches; and the other of the first or second surface roughnessis less than 20μ inches.
 25. The thermoplastic structure as recited inclaim 23, wherein the second surface roughness is up to 25 times that ofthe first surface roughness.
 26. A decorative, translucent thermoplasticstructure prepared from a plurality of dissimilar resin materials tohave the appearance of a unitary structure having a color diffusedthroughout its composition, the structure comprising: a transparentresin substrate having opposing front and back surfaces and a pluralityof adjacent edges that separate the opposing viewing surfaces by 0.500inches to 1 inch, the transparent resin substrate comprising a firstresin material, wherein the front or back surface comprises a bondingsurface having a first surface roughness; a translucent colored filmmade of a second resin material that is dissimilar to the first resinmaterial, but that is nevertheless miscible with the first resinmaterial, the translucent colored film having a bonding surface with asecond surface roughness that is different from the first surfaceroughness, the bonding surface of the translucent colored film beingfused to and intermixed with the bonding surface of the transparentresin substrate without any air pockets being trapped therein; and atexture having been uniformly applied to all surfaces of a completedpanel comprising the fused combination of the resin substrate andcolored film layer; wherein the uniformly applied texture combined withthe intermixing of the combined resin substrate and colored film layercooperate to diffuse the color of the colored film throughout thethermoplastic structure regardless of viewing angle on each viewingsurface, and substantially uniformly on the plurality of adjacent edges.27. The thermoplastic structure as recited in claim 26, wherein thetransparent resin substrate comprises PETG, and the translucent coloredfilm comprises PVC or PCTG.
 28. The thermoplastic structure as recitedin claim 26, wherein: the first resin material is selected from thegroup consisting of PVC, polyester, acrylic, polycarbonate, andcombinations thereof; and the second resin material is a dissimilarresin material selected from the same group, such that the second resinmaterial is dissimilar to the first resin material selected from thegroup.
 29. The thermoplastic structure as recited in claim 26, whereinboth the transparent resin substrate and the translucent colored filmcomprise a surface roughness having an even distribution of texturegranules.
 30. The thermoplastic structure as recited in claim 26,wherein: the transparent resin substrate and the translucent coloredfilm layer are fused together through application of heat and pressure;and the heat applied during the fusing process exceeds theglass-transition temperature (Tg) of each of the transparent resinsubstrate and the translucent colored film layer.
 31. The thermoplasticstructure as recited in claim 26, wherein the thermoplastic structure isdevoid of entrapped air or color streaking.
 32. The thermoplasticstructure as recited in claim 26, wherein the uniformly applied textureis mechanically applied.
 33. The thermoplastic structure as recited inclaim 32, wherein the uniformly applied texture is imparted via one ormore textured rollers.
 34. The thermoplastic structure as recited inclaim 26, wherein: one of the first surface roughness or the secondsurface roughness is greater than 20μ inches; and the other of the firstor second surface roughness is less than 20μ inches.
 35. Thethermoplastic structure as recited in claim 26, wherein the secondsurface roughness is up to 25 times that of the first surface roughness.